Intermediate structure for integrated circuit devices

ABSTRACT

A structure useful during the fabrication of semiconductor integrated circuits. At least one layer is formed over an insulating layer, and an opening formed to an underlying substrate. A conductive layer is formed over the at least one layer, which simultaneously forms a conductive plug in the bottom of the opening. An insulating layer plug is formed over the conductive plug to provide protection while the conductive layer on the at least one layer is removed.

This is a division of application Ser. No. 08/110,486, filed Aug. 23, 1993, now U.S. Pat. No. 5,423,939 which is a Continuation of application Ser. No. 07/809,937, filed Dec. 18, 1991, now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to integrated circuits, and more specifically to a method for forming contact vias in integrated circuits.

2. Description of the Prior Art

As integrated circuit devices become more complex, greater numbers of interconnect levels are required to connect the various sections of the device. Generally contact vias are formed between interconnect levels to connect one level to another. When multiple layers of interconnect are used in this manner however, difficulties arise in forming upper interconnect levels and contact vias due to the uneven topographical features caused by the lower interconnect levels. Thus, the topography of interconnect layers affects the ease of manufacturing of the integrated circuit device.

The uneven topographical features of multiple interconnect levels are caused by forming the various interconnect layers above each other, resulting in the creation of hills and valleys on the surface of the device. Those skilled in the art will recognize it is difficult to get upper interconnect layers to maintain constant cross-sections when crossing over uneven topography. This leads to portions of the interconnect lines having a higher current density, leading to electromigration problems and related device failure mechanisms. These step coverage problems can result in voids and other defects in the interconnect signal lines themselves, and in the contact vias formed between interconnect lines.

Therefore, it would be desirable to provide a method for forming contact vias which are free of voids and other defects, and which result in a more planar topography. It is also desirable that such a method not significantly increase the complexity of the manufacturing process.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a method for forming contact vias in integrated circuits which are free of defects caused by step coverage problems.

It is another object of the present invention to provide such a method which results in a more planar topography.

It is another object of the present invention to provide such a method and structure which is compatible with standard process flows, and which add minimal additional complexity to the fabrication of a typical integrated circuit.

Therefore, according to the present invention, a method is provided for forming contact vias in an integrated circuit. Initially, a first protective layer is formed on an insulating layer, and an opening is created through the insulating layer where a contact is to be made. A conductive layer is deposited over the protective layer and partially fills the opening, forming a conductive plug in the opening. A second protective layer is then formed over the conductive plug. Portions of the conductive layer which were formed over the first protective layer are removed. During removal of those portions of the conductive layer, the second protective layer protects the conductive plug from damage. The first and second protective layers are then removed, leaving the conductive plug in the opening in the insulating layer.

A conductive contact can now be made by depositing a second conductive layer over the conductive plug.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, and further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

FIGS. 1-6 are sectional view illustrating one preferred method for forming a contact via in integrated circuits according to the present invention; and

FIGS. 7-11 are sectional views illustrating an alternative preferred method for forming contact vias in integrated circuits according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The process steps and structures described below do not form a complete process flow for manufacturing integrated circuits. The present invention can be practiced in conjunction with integrated circuit fabrication techniques currently used in the art, and only so much of the commonly practiced process steps are included as are necessary for an understanding of the present invention. The figures representing cross-sections of portions of an integrated circuit during fabrication are not drawn to scale, but instead are drawn so as to illustrate the important features of the invention.

Referring to FIG. 1, a contact is to be formed on an underlying region 10 in an integrated circuit. The underlying region 10 can be either a semiconductor substrate or interconnect signal line. A first insulating layer 12, typically made of oxide, is grown or deposited on the device. A photoresist mask 14 is then deposited on the insulating layer 12 and patterned, and an opening 16 is etched through the insulating layer 12 where a contact is to be made.

FIG. 2 illustrates the integrated circuit after a conductive layer 18 is deposited over the device. The conductive layer 18 covers the photoresist layer 14 and partially fills the opening 16, forming a conductive plug 20 in the opening. In this example of the preferred embodiment the conductive layer 18 and conductive plug 20 are made of aluminum, but they can be made of other conductive materials. The aluminum is preferably deposited by sputtering, so that it tends to deposit only on horizontal surfaces. This leaves little or no aluminum along the vertical sidewalls of the opening 16, so that the layer 18 and plug 20 are effectively detached.

Referring to FIG. 3, a protective layer 22 is deposited over the device and extends into the opening 16. In this example of the preferred embodiment, the protective layer 22 is formed using a low viscosity photoresist, but it can also be made from other materials.

FIG. 4 illustrates the device after a portion of the protective layer 22 is removed. Either, a chemical or plasma etch can be performed to etch back the protective layer 22 to approximately the point where the conductive layer 18 makes contact with the photoresist layer 14. A chemical etch is then performed to remove those portions of the conductive layer 18 which cover the photoresist layer 14 (not shown). The protective layer 22 remaining in the opening 16 protects the conductive plug 20 from damage during removal of the conductive layer 18.

The protective layer 22 remaining in the opening 16 and the photoresist layer 14 are then removed, leaving the structure shown in FIG. 5. An isotropic etch can be used, for example, to remove the two layers. A second conductive layer 24, such as a metal layer, could then be deposited over the device as shown in FIG. 6 and patterned to define an interconnect signal line.

FIGS. 7-11 illustrate an alternative method which can be used to form a contact structure in an integrated circuit. Referring to FIG. 7, a contact is to be formed on an underlying region 26 in an integrated circuit. The underlying region 26 can be either a semiconductor substrate or an interconnect signal line. A first insulating layer 28, typically made of oxide, is grown or deposited over the device. A barrier layer 30, typically made of silicon nitride, is deposited over the first insulating layer 28, followed by a second insulating layer 32. The second insulating layer 32 is typically made of oxide. A photoresist mask 34 is then deposited and patterned over the second insulating layer 32, and an opening 36 is formed through the second insulating layer 32, the barrier layer 30, and the first insulating layer 28.

FIG. 8 illustrates the integrated circuit after the photoresist mask 34 is removed and a conductive layer 38 is deposited over the device. The conductive layer 38 covers the second insulating layer 32 and partially fills the opening 36, forming a conductive plug 40 in the opening 36. In this example of the preferred embodiment, the conductive layer 38 and conductive plug 40 are made of aluminum, but they can be made of other conductive materials. The aluminum is preferably deposited by sputtering, so that it tends to deposit only on horizontal surfaces. This leaves little or no aluminum along the vertical sidewalls of the opening 36, so that the layer 38 and plug 40 are effectively detached.

Referring to FIG. 9, a dielectric layer 42 is deposited over the conductive layer 38 and extends into the opening 36. In this example of a preferred embodiment, the dielectric layer 42 is made of spin on glass, but it can also be made of other materials. The dielectric layer 42 is then etched down to approximately the point where the conductive layer 38 makes contact with the second insulating layer 32 (not shown). The etch back can be done, for example, by performing an isotropic etch.

FIG. 10 illustrates the integrated circuit after portions of the conductive layer 38 are removed, typically by performing an isotropic etch. The dielectric plug 44 protects the conductive plug 40 from damage during removal of portions of the conductive layer 38. The dielectric plug 44 and second insulating layer 32 are then removed, followed by removal of the barrier layer 30. Barrier layer 30 acts as an etch stop to protect the underlying insulating layer 28. Each of these removal steps can be done, for example, by performing an isotropic etch designed to remove each material.

Following removal of the conductive plug 44, the second insulating layer 32 and the barrier layer 30, a contact structure as shown in FIG. 11 is formed. As can be seen, the structure depicted in FIG. 11 is similar to the contact structure shown in FIG. 5. The integrated circuit is now ready for further processing steps, such as the step described in reference to FIG. 6.

Those skilled in the art will recognize that the methods described above alleviate step coverage problems typically encountered when forming contact structures. Protecting the conductive plug during removal of the conductive layer ensures a good contact can be made between interconnect levels. Furthermore, the presently claimed invention can be used to fill all contact vias in a device, regardless of their size. 

What is claimed is:
 1. An intermediate structure useful during fabrication of a semiconductor device, comprising:an insulating layer over a substrate; a layer of photoresist on the insulating layer; an opening through the photoresist layer and the insulating layer exposing a portion of the substrate; a conductive layer on the photoresist layer; a conductive plug in the opening and filling the opening to a depth approximately equal to a thickness of the insulating layer, wherein the conductive plug and conductive layer are formed from the same material; and a protective cap within the opening and completely covering the conductive plug.
 2. The structure of claim 1, wherein the insulating layer comprises oxide.
 3. The structure of claim 1, wherein the conductive plug and conductive layer comprise aluminum.
 4. The structure of claim 1, wherein the protective cap completely fills the opening and also lies on and covers the conductive layer.
 5. The structure of claim 1, wherein the protective cap is contained within the opening, and has a thickness less than a combined thickness of the photoresist layer and the conductive layer.
 6. An intermediate structure useful during fabrication of a semiconductor device, comprising:a first insulating layer on a substrate; a barrier layer on the insulating layer; a second insulating layer on the barrier layer; an opening through the second insulating layer, the barrier layer, and the first insulating layer to expose a portion of the substrate; a conductive plug filling the opening to a first thickness equal to a thickness of the first insulating layer; and a third insulating layer within the opening and having an upper surface below an upper surface of the second insulating layer.
 7. The structure of claim 6, further comprising a conductive layer on the second insulating layer, wherein the conductive layer and the conductive plug are formed of the same material.
 8. The structure of claim 7, wherein the third insulating layer completely fills the opening and covers the conductive layer.
 9. The structure of claim 7, wherein the conductive plug and the conductive layer comprise aluminum.
 10. The structure of claim 7, wherein the first and second insulating layers comprise oxide.
 11. The structure of claim 7, wherein the third insulating layer comprises spin-on-glass.
 12. The structure of claim 7, wherein the barrier layer comprises nitride.
 13. The structure of claim 6, wherein the conductive plug and the conductive layer comprise aluminum.
 14. The structure of claim 6, wherein the first and second insulating layers comprise oxide.
 15. The structure of claim 6, wherein the third insulating layer comprises spin-on-glass.
 16. The structure of claim 6, wherein the barrier layer comprises nitride. 